Success stories
How to automate conveyor cleaning and recover production hours in industrial baking
Project description
An industrial bakery with continuous production contacted us because the cleaning of its modular conveyors had become a recurring problem.
Original situation:
Challenges posed by the client:
In this industrial bakery with continuous production, the cleaning of its modular conveyors had become a recurring problem.
The plastic modular belts, used in different stages of the process, accumulated dough, flour and grease residues that required frequent and thorough cleaning.
The procedure was completely manual. It was carried out by means of pressurized water, chemical product application and subsequent rinsing, which meant that the line had to be stopped for several hours during each cleaning cycle. These stoppages not only affected production planning, but also directly reduced the actual availability of the installation.
In addition, water consumption was high and the use of detergents and disinfectants was a significant operating cost. Moisture generated during the process caused accumulations under the belts and in areas that were difficult to access, increasing the microbiological risk and complicating complete drying before restarting production.
But the underlying problem was not only time or consumption. The customer told us that cleaning depended to a large extent on the operator: it was not homogeneous, it was not repeatable and it was not standardized. In a highly automated factory, hygiene was still a manual, variable and inefficient process.
The need was clear: to automate conveyor cleaning, reduce consumption, minimize downtime and guarantee a constant, safe and controlled result.
Proposed solution:
Customized steam solution developed by Giconmes.
Proposed solution:
After analyzing the process and the actual operating conditions, Giconmes proposed the installation of a Jet System specifically designed for modular conveyors in the food industry.
The key element of the system is a rotating spinner, which projects jets of high-pressure steam dynamically and uniformly onto the belt surface. Thanks to its rotational movement, the spinner generates a constant and homogeneous impact, allowing the removal of dough, grease and adhering particles even in the micro-cracks characteristic of modular conveyors.
The system is powered by a 20 kW electric steam generator, which supplies dry steam in an instantaneous and controlled manner. This configuration makes it possible to concentrate thermal energy directly on the cleaning area, without the need for large water consumption or the application of chemicals.
Unlike the traditional system based on pressurized water and detergents, the implemented solution combines:
- Steam thermal energy.
- Mechanical impact generated by the rotating spinner.
- Automation of the cleaning cycle.
The Jet System was integrated into the production line, allowing programmed cycles to be run without disassembling the belt and with minimal operator intervention. In this way, cleaning went from being a manual, long and variable procedure to an automated, repeatable and controlled process.
Technology used:
- 20 kW electric steam generator.
- Jet System with 110 mm spinner.
CHALLENGES
We meet customer requirements
Steam solution for cleaning in a food industry company. We achieved the following results:
Automated, repeatable and controlled cleaning process by means of Jet System with rotary spinner integrated in the line.
Efficient removal of dough, flour and adhering grease, even in micro-cracks of the modular conveyor without disassembly.
Full integration into existing operations, with programmed cycles and minimal operator intervention.
Substitution of the manual system with water and detergents, reducing variability, consumption and dependence on the human factor.
Do you need a customized solution?
We help you define what type of installation you need
There are no emissions beyond those produced during the electricity production process. Consequently, emissions can be neutral depending on the electricity mix. Electric steam boilers are the present and the future.
Absolutely. In fact, it is recommended to achieve maximum efficiency. There is no problem with remote control as long as it complies with current regulations.
A steam generator is a pressure vessel that, together with the piping network, is subject to regulatory control and complementary technical instructions, according to the regulations published in Royal Decree 809/2021, of September 21. Maintenance is divided into a part that can be easily fulfilled by the owner:
- Know and apply the manufacturer’s instructions regarding use, safety measures, and maintenance.
- Not to put the installation into service or prevent the operation of pressure equipment if the requirements of the Regulation are not met.
- Having at least the following documentation for the pressure equipment while they are installed: Declaration of conformity, manufacturer’s instructions (if applicable), and, if necessary, installation certificate, along with other supporting documentation (such as installation project, record of the last periodic inspection, certifications of equipment repairs or modifications, and any other documentation required by the relevant technical instruction complementary to this regulation). For detailed contents, refer to Annex IV of the regulation. Making this documentation available to the competent authority of the autonomous community and the companies responsible for maintenance, repair, or periodic inspections.
- Use the pressure equipment within its intended operating limits as specified by the manufacturer and take it out of service if it no longer meets the necessary safety requirements.
- Perform maintenance on the installations, pressure equipment, safety accessories, and control devices in accordance with the operating conditions and manufacturer’s instructions, and examine them at least once a year.
- Arranging for the necessary periodic inspections as required by Article 6 of the regulation.
- Having and maintaining an up-to-date record of pressure equipment categories I to IV, as defined in RD 709/2015, of July 24, or equipment similar to these categories according to Article 3.2 of the regulation, as well as their installations.
It is known that by applying heat to water, it transforms into steam at the boiling point and atmospheric pressure. From there, depending on the required saturation degree of steam for its proper application, we need to increase the pressure to obtain a higher temperature. To change the temperature and saturation degree of steam, we always need to modify the pressure.
It is a unit of pressure equivalent to 1 kg/cm2, 0.98 atmospheres, or 14.50 PSI.
Haven't found the answers to your questions?
Please send us a question or download all the information
USES OF STEAM IN INDUSTRY AND OTHER BUSINESSES
Other similar success stories using steam
The use of steam is gaining popularity in several industries due to its efficiency and environmental benefits..
In our "Success Stories" section, you can discover more about companies that have adopted this technology and have achieved successful results in terms of efficiency and sustainability. Click on the success stories to learn more details.
Original situation: Challenges posed by the client: In this company in the food sector, cleaning was carried out using pressurized water, but the system had significant limitations: At the same time, the company was immersed in a process to improve its environmental performance, with the objective of complying with and reinforcing standards such as: In […]
How to eliminate downtime due to loss of traction on conveyors without disassembly and without water
Original situation: Challenges posed by the client: During normal operation of the line of one of the main meat preparation companies in Spain, there was a progressive accumulation of dirt on the inside face of the conveyor belts. This dirt generated a loss of traction between the belt and the rollers. As a consequence: According […]